PROJECT REPORT ON ASSEMBLY LINE BALANCING IN A MANUFACTURING CONCERN A DISSERTATION SUBMITTED IN PARTIAL FULFILLMENT OF REQUIREMENT OF M.TECH. DEGREE IN INDUSTRIAL ENGINEERING Submitted by AKHILESH BARVE (2000 MEI 017) Under the guidance of Dr. J.M.MAHAJAN MECHANICAL ENGINEERING DEPARTMENT IIT DELHI Indian Institute of Technology Delhi
BPI. Limited C-33. Phase-II. Noida. Gautam Budh Nagar (U.P.) 201305 India Phone : 0118-4562074/75/76/77 Fax : 0118-4562162 CERT:HR:01 December 08, 2001 TO WHOMSOEVER IT MAY CONCERN THIS IS TO CERTIFY THAT, AKHILESH BARVE SIO MR. RAJENDRA KUMAR BARVE, M.TECH. STUDENT OF IIT DELHI, HAS SUCCESSFULLY COMPLETED A PROJECT IN OUR ORGANISATION, IN THE FIELD OF "INDUSTRIAL ENGINEERING" FROM MAY 2001 TO DECEMBER 2001. WE WISH HIM ALL SUCCESS IN HIS FUTURE ENDEAVOURS. S K DAS GENERAL MANAGER Registered Office : BPL Works. Pafakkad 678 007. Herala.
CERTIFICATE This is to certify that dissertation entitled "Assembly line balancing in a manufacturing concern" submitted by Mr. Akhilesh Barve (2000MEI017) in the partial fulfillment of the requirement of the degree of Master of Technology in Industrial Engineering, is the record of bonafide work under my guidance and supervision. This work has not been submitted anywhere else for any degree or diploma. Dr. J.M. Mahajan Department Of Mechanical engineering Indian Institute Of Technology, Delhi (i)
ACKNOWLEDGEMENT I wish to acknowledge with a deep sense of gratitude, my indebtedness to Dr. J M.Mahajan, Department of Mechanical Engineering, Indian Institute of Technology, Delhi, for his incessant guidance and consistent encouragement throughout the period of project work. I would also like to thank the entire Industrial Engineering faculty, which taught me how to think logically and rationally. I am also indebted to the TIT library whose resources I frequently consulted and which formed basis of my study. My sincere thanks are due to General Manager Mr. S K DAS of BPL Limited, Noida and other staff of BPL Limited for extending all possible help and cooperation in my work. AKHILESH BARVE
ABSTRACT The work reported in this thesis deals with the analysis and design of assembly line BPL Limited, Noida, a television manufacturing plant. It deals with the design of assembly line, to achieve certain specified production rate. The main objective was to look for the most efficient and economical system. In method improvement only those operations were considered which offered maximum potential for savings. Flow diagrams were prepared for the selected operations, so as to examine them critically and see how the assembly time could be reduced. Heuristic method of sequencing of assembly-line technique was used for balancing the line, taking into consideration the variability of task time and the situation where some of the element times are greater then cycle time. In dealing with the situation following aspects were considered. Method improvement Time study Methods for line balancing Key words: Assembly line, Precedence diagram, Work station, Two handed process chart, Time observation sheet, Flow process chart.
Contents CERTIFICATE (0 ACKNOWLEDGEMENT ABSTRACT LIST OF TABLES AND FIGURES ABBREVIATIONS CHAPTER-1: INTRODUCTION 1 (ii) (iii) 1.1 Line Balancing 2 1.2 Assembly Line System 3 1.3 Motivation 5 1.4 Objective 7 CHAPTER-2: LITERATURE SURVEY 8 (iv) 2.1 Work done earlier in IITD 11 2.2 Statement of Problem 11 CHAPTER-3: PROFILE OF THE COMPANY 12 3.1 BPL Group of Companies 12 3.2 About the Noida Plant 13 3.3 Assembly line in Company 14 CHAPTER-4: PROBLEM IDENTIFICATION 18 CHAPTER-5: THEORETICAL APPROACH 22 5.1 Terminology 22 5.2 Methods of Line Balancing 25 5.3 Heuristic Approach of Line Balancing 29 5.4 Method and Time Study Concepts 32 CHAPTER-6: DATA COLLECTION AND ANALYSIS 39 CHAPTER-7: RESULTS AND CONCLUSION 73 CHAPTER-8: FURTHER SCOPE OF STUDY 75 REFERENCES 76 APPENDIXES 1. Flow Process Chart. 2. Two Handed Process Chart (v) Ki4